Heat Transfer
Fiber-reinforced composites, widely used across various industries, consist of reinforcing fibers embedded in a matrix. During the curing process, this mixture transforms into a stable material. Curing is a critical step to ensure the durability and strength of the final product. In one of our intermediate packages, we used Abaqus to analyze the curing process in composites with linear elastic models. While these models are straightforward and user-friendly, their accuracy is limited because composites exhibit viscoelastic behavior during curing, rather than elastic behavior.
To address this limitation, the current package introduces two more advanced and accurate models for analyzing residual stresses in composites: the viscoelastic model and the path-dependent model. These models offer significantly greater accuracy compared to linear elastic ones but involve added complexity. To simplify this complexity for users, the package begins with a comprehensive overview of the underlying theories and formulations for the viscoelastic and path-dependent models. It then provides detailed guidance on implementing these models using Abaqus subroutines. Finally, workshops are included to demonstrate how the viscoelastic model significantly improves the prediction of residual stresses in composites compared to the elastic models featured in our intermediate package.
Laser Assisted Machining (LAM): Modeling and Simulation in Abaqus/CAE
In this tutorial, a comprehensive discussion on modeling and simulation of laser assisted machining is presented. It includes building FEM-based models of machining, laser heating, and laser-assisted machining models in Abaqus/CAE. The finite element method (FEM) simulation is based on the coupled thermo-mechanical behavior. The package walks learners through building models that simulate the impact of laser heating on the workpiece. Detailed lessons cover constructing basic machining and laser heating models, setting boundary conditions like cutting speed and laser power, and writing subroutines such as DFLUX and VDFLUX to simulate laser heat sources. Additionally, learners will perform analyses to study temperature distribution, and stress-strain behavior. Through parametric analysis and comprehensive result evaluation, learners will gain a deep understanding of temperature distribution, stress behavior, and how laser heating can improve the machining process.
Note: All Simulation files and half of the videos are available now.
Additive Manufacturing (AM), a revolutionary layer-by-layer fabrication technology, is transforming how products are designed and manufactured. This comprehensive tutorial package focuses on the Inherent Strain (IS) method, a highly efficient numerical approach for simulating the Laser Powder Bed Fusion (LPBF) process in metal additive manufacturing. The detailed thermo-mechanical simulation of the Laser Powder Bed Fusion (LPBF) for complex geometric parts requires a large number of time steps to estimate residual stress and distortion, which is not computationally cost-effective. Furthermore, based on the large thermal gradient near the heat source, the mesh size must be sufficiently small to accurately predict the induced residual stress and distortion of the deposited layers in the heat-affected zone. Therefore, applying a coupled thermo-mechanical analysis for multiple laser scans with a fine mesh model to macro-scale simulation would incur excessively large computational costs.
Additionally, the large number of degrees of freedom for each element in the mechanical analysis leads to higher complexity as well as a longer amount of processing time. Detailed thermo-mechanical analysis for an industrial component is almost impractical since it would demand hundreds of terabytes of memory and years to calculate. Therefore, to overcome the huge computational burden associated with the numerical simulation of the LPBF caused by the infinitesimal laser spot size and thousands of thin layers with a thickness at the micron level, the Inherent Strain Method in additive manufacturing has been widely used in research and commercial software.
In this tutorial, the Inherent Strain Method additive manufacturing approach is presented both theoretically and practically in Abaqus. An agglomeration approach will be considered to transfer an equivalent inherent strain from both micro-scale and macro-scale modeling strategies. The implementation of this approach is explained step by step, accompanied by various workshops in micro-scale and macro-scale models for different geometries. This training package enables you to write your subroutine codes and Python scripting, as well as have more control over the LPBF process simulation.
Abaqus shaft slip ring simulation | Using Python scripts for parametric analysis
The shaft slip ring is a crucial component enabling the transfer of power and signals in rotating systems. So, this tutorial delves into the intricate Abaqus shaft slip ring analysis. It focuses primarily on the mechanical aspects, offering insights into displacement, stress fields, and strains through the shaft analysis Abaqus model. The tutorial utilizes parametric modeling and Python scripting for the Abaqus shaft slip ring simulation. So, it enables you to optimize geometric parameters, material properties, and loading conditions, enhancing efficiency in modeling processes. It addresses complexities such as creep behavior and material interactions, providing a comprehensive approach tailored for realistic simulations. The tutorial meets various project requirements, supporting them with practical examples and adaptable simulation files.
Laser Forming Process Tutorial in Abaqus
The laser forming process is performed by applying thermal stresses to the workpiece surface by heating the surface with a laser beam. These internal stresses induce plastic strains in the part resulting in local elastic-plastic deformation (Laser-induced plastic deformation). In this laser forming simulation tutorial the DFLUX subroutine is used to apply heat flux (Gaussian heat distribution) dependent on location and time in finite element simulation. For example, the linear heating processes of laser forming and welding (with a slight simplification) can be simulated by this subroutine. In the linear heating process, by applying heat flux to the surface of a sheet, a thermal gradient is created in its thickness. This thermal gradient causes permanent deformation of the sheet. To simulate the laser forming process, it is necessary to apply a time and location-dependent heat flux to the sheet. In this type of loading, a heat flux is applied on the plate, which is defined using the DFLUX subroutine, including the laser power, movement speed, beam diameter, absorption coefficient, and laser movement path according to the designed experiments (Laser forming process parameters). To verify this Abaqus laser forming simulation, the simulation results and experimental results of sheet deformation (U) are compared. The displacement of the sheet in the simulation is in good agreement with the experimental results.
Friction Stir Welding simulation Tutorial | FSW Advanced level
Friction stir welding (FSW) involves complex material flow and plastic deformation. Welding parameters, tool geometry, etc., have important effects on the material flow pattern, heat distribution, and eventually on the structural evolution of the material. In an Abaqus friction stir welding example, the rotational movement of the tool and its friction in contact with the workpiece causes heat generation, loss of strength, and an increase in material ductility around the tool. The feeding movement of the tool causes the material to transfer from the front of the tool to the back of it, and eventually leads to a join. Therefore, heat plays an important role in this process, and parameters such as rotational speed, tool feeding speed, tool geometry, and others, all somehow have a significant impact on controlling the amount of incoming heat, the disturbance and flow pattern of the material, the evolution of the microstructure, and the quality of the resulted weld. This friction stir welding example simulation tutorial shows you how to simulate the Abaqus FSW simulation process in such a way that you can accurately predict the effect of all relevant parameters on the process. In most of the implemented projects, welding mud, and welding defects (welding overfills and overlaps, weld gaps) are not visible and predictable; however, in this simulation, these cases are visible. This project is designed to enhance participants' understanding of how to accurately simulate the FSW process to see the weld's general appearance.
LPBF Printing Simulation in Abaqus | 3D Printing with Laser Powder Bed Fusion Process (LPBF) Method
3D printing is a process of creating three-dimensional objects by layering materials, such as plastic or metal, based on a digital design. 3D printing simulation involves using software to predict and optimize the printing process, allowing for more efficient and accurate production. This educational package includes two 3D printing modeling methods. The first method is based on the use of subroutines and Python scripting. After an introduction to the 3D printing process, the first method with all of its detail is explained; then, there would be two workshops for this method; the first workshop is for the 3D printing simulation of a gear with uniform cross-section and the second one is for a shaft with non-uniform cross-section. The second method uses a plug-in called AM Modeler. With this plug-in, the type of 3D printing can be selected, and after inserting the required inputs and applying some settings, the 3D printing simulation is done without any need for coding. Two main workshops will be taught to learn how to use this plug-in: "Sequential thermomechanical analysis of simple cube one-direction with LPBF 3D printing method using the trajectory-based method with AM plug-in" and "3D printing simulation with Fusion deposition modeling and Laser direct energy deposition method with AM plug-in".
FDM Simulation in Abaqus | Simulating 3D Printing with Fused Deposition Modeling
3D printing is the process of fabricating objects in three dimensions by adding layers of materials, such as plastic or metal, based on a digital design. Simulation for 3D printing involves the use of software to predict and optimize the printing process, enabling more efficient and precise production. This educational package includes a simulation specifically for 3D printing using Fused Deposition Modeling (FDM). The FDM simulation employs a plug-in known as AM Modeler, which allows users to select the desired 3D printing method. By inputting the necessary parameters and adjusting settings, the 3D printing simulation can be performed without requiring any coding. A workshop will be conducted to teach participants how to utilize this plug-in effectively, focusing on "3D printing simulation with Fused Deposition Modeling and Laser Direct Energy Deposition method using the AM plug-in."
Curing process simulation in Abaqus
Fiber-reinforced composites have found widespread use across various fields due to their remarkable properties. This necessitates a careful design of their manufacturing processes to attain industrial application quality. The critical factor influencing their quality is the curing process, wherein the resin transforms into a solid state under temperature cycles. However, the challenge lies in achieving optimal curing quality while maintaining production efficiency. To overcome this challenge, an effective approach involves utilizing numerical simulations to optimize temperature cycles during curing. Nonetheless, creating such a model is complex as it must consider multiple factors concurrently, including temperature release from chemical reactions, shrinkage strains, and stress resulting from temperature variations, topics covered in this package. The package begins with an introduction to fiber-reinforced composites, exploring their advantages, applications, and categorization. It guides you through the fabrication process, detailing curing techniques and associated challenges. Furthermore, the package introduces constitutive equations for simulating the curing process and the necessary Abaqus subroutines for implementation. Additionally, two practical workshops are included to offer experience in modeling the curing process with Abaqus. These workshops enable you to evaluate internal heat generation and analyze strain and stress distributions. They not only provide guidance on simulation and subroutine implementation but also are provided for verification purposes.
Arc welding simulation in Abaqus
Notice: This package will be available one week after purchase.
Arc welding is a fusion process that involves joining metals by applying intense heat, causing them to melt and mix. The resulting metallurgical bond provides strength and integrity to the welded joint. Arc welding is widely used in various industries for fabricating structures and components. Arc welding simulation in Abaqus is essential for optimizing the welding process and ensuring high-quality welds. It allows engineers to predict and analyze factors such as temperature distribution, residual stresses, distortion, and microstructure evolution during welding. By accurately simulating the welding process, parameters like welding speed, heat input, and electrode positioning can be optimized to achieve desired weld characteristics and minimize defects.
Friction Stir Welding (FSW) Simulation in Abaqus
Friction stir welding (FSW) is a solid-state joining process that utilizes a rotating tool to generate frictional heat, enabling the consolidation of materials without melting. FSW offers numerous benefits and is particularly valuable for welding challenging materials like aluminum alloys. It finds widespread applications in industries such as automotive, aerospace, shipbuilding, and construction, providing enhanced strength, weight reduction, and structural integrity. FSW minimizes distortion, reduces the need for post-weld machining, and eliminates issues related to solidification and cooling. Simulations using Abaqus, a popular finite element analysis software, play a crucial role in optimizing FSW processes. Engineers can investigate process parameters, evaluate weld quality, predict residual stresses and distortions, and optimize weld designs through Abaqus simulations. These simulations enable cost-effective development, improved weld quality, reduced material waste, and enhanced productivity in industrial applications. In this package, you will learn how to simulate FSW simulations in a variety of examples with different methods.
Car part industrial simulation
Car industrial parts are complex and critical components that play a vital role in the operation of a car. Two such parts are the exhaust manifold and the internal combustion engine (IC engine). The exhaust manifold directs hot exhaust gases from the engine's cylinders into the exhaust system and is typically made of cast iron or stainless steel. The IC engine converts fuel into mechanical energy by burning fuel in a controlled explosion within the engine cylinder. High temperatures and pressures must be considered in the design, and the components must be made of durable materials that can withstand the stresses of constant combustion. Therefore, it is important to know how these parts respond under different loading conditions to have the best design possible. In this package, there are two workshops to help you with this job: Heat transfer analysis in an exhaust manifold and Thermomechanical analysis of an exhaust manifold.
The aim of fire analysis is to evaluate the performance of structures in real fire scenarios and to develop strategies to improve their fire resistance and safety. Fire analysis is commonly used in the design and evaluation of buildings, bridges, and other structures. Fire analysis is the process of simulating the behavior of structures under fire conditions. Fire analysis typically involves two main steps: (i) heat transfer analysis to estimate the propagation of heat in the structure and (ii) structural analysis taking into account the effects of heat and mechanical loads. In this package, you will learn how to do a fire simulation on some structures and parts like concrete beams. You can find more details about how to do this simulation in the description of the workshops.
A tunnel is an underground or underwater passage for transportation, utility lines, or water pipelines. Tunnels are critical infrastructure, and their safety and reliability are essential for ensuring public safety and the smooth functioning of society. Tunnel simulation involves using computer models to predict the behaviour of tunnels under different types of loading conditions, such as earthquakes, floods, or explosions. These simulations can help engineers and policymakers assess the safety and reliability of tunnels, identify potential failure modes, and develop strategies to mitigate risks. By using advanced simulation techniques, engineers can better understand the complex behavior of tunnels and design more effective and durable structures. Tunnel simulation is an essential tool for ensuring the safety and resilience of tunnels and the infrastructure they support. Some workshops are presented in this package to teach you how to simulate and analyze tunnels in Abaqus; two of these workshops are Damage analysis of an underground box tunnel subjected to surface explosion and Tunnel dynamic analysis subjected to internal blast loading using CEL method.
An explosion is a rapid and violent release of energy, usually accompanied by a loud noise, heat, and pressure waves. Explosions can be caused by a variety of factors such as chemical reactions, combustion, nuclear reactions, or mechanical failure. Explosions can cause severe damage to buildings, infrastructure, and human life. To minimize the impact of such incidents, accurate and reliable simulation of explosions is crucial. Explosion simulation involves modeling the complex interactions of blast waves, shock waves, and debris with the surrounding environment. By simulating explosions, engineers and scientists can identify potential risks and develop effective safety measures. In this package, you will learn how to model explosions in different situations with practical examples, such as Air blast explosion simulation inside an RC room and Subsurface explosion simulation on buried steel pipelines.
Additive manufacturing simulation with Abaqus subroutine & python | 3D printing Python
3D printing is a technique for creating three-dimensional objects by layering materials such as plastic or metal based on a digital design. 3D printing simulation involves the use of software to predict and enhance the printing process, resulting in more efficient and precise production. This training package is based on the use of subroutines and Python scripting. Following an introduction to the 3D printing process, this method with all its details is explained. Two workshops are then conducted for this method. The first workshop covers 3D printing simulation of a gear with a uniform cross-section, while the second workshop covers a shaft with a non-uniform cross-section.
Thermal Heat Transfer in Abaqus
This package is related to Thermal Analysis in Abaqus. This package helps Abaqus users to simulate professionally.
In general, Abaqus can solve the following types of heat transfer problems (For thermal and thermo-mechanical problems):
- Uncoupled heat transfer analysis
- Sequentially coupled thermal-stress analysis
- Fully coupled thermal-stress analysis
- Adiabatic analysis
Analysis of Heat Transfer in Abaqus
This Analysis of Heat Transfer in Abaqus package includes workshops that help you to fully learn how to simulate the temperature distribution and heat flux in solids under thermal loads. This tutorial package enables you to model thermal responses including all the modes of heat transfer, namely conduction, convection and radiation. The subjects such as using film conditions to simulate the convective heat transfer, the dissipation of the frictional heat generated, thermomechanical analysis and etc. are covered in this package
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HETVAL is a user subroutine specifically developed to address the limitations of Abaqus in accurately handling volumetric heat flux resulting from internal heat generation within materials. The subroutine’s functionality depends on factors such as time, temperature, or evolving state variables, stored as solution-dependent variables. Accordingly, it can tackle scenarios involving phase changes during simulations. Moreover, the subroutine allows the integration of kinetic theory to account for phase changes associated with internal heat release, such as predicting crystallization in polymer casting processes. Such a multi-functional subroutine finds applications in heat transfer analyses, coupled thermal-electric studies, or temperature-displacement analyses. In this package, our primary goal is to provide valuable insights into the HETVAL subroutine and its diverse applications. Afterward, through a series of comprehensive workshops, we will guide participants in utilizing HETVAL under various conditions. In the final workshop, a problem will be presented, allowing you to explore a realistic example and gain hands-on experience in simulating the curing process within fiber-reinforced composites using HETVAL. Furthermore, to assist those unfamiliar with fiber-reinforced composites, we have included an introductory lesson covering their applications, significance, and an explanation of the importance of accurately simulating the curing process. By completing this package, you will have gained a comprehensive understanding of utilizing HETVAL across various conditions and scenarios. Moreover, you will have acquired the ability to simulate the heat generated during the curing process of fiber-reinforced composites, demonstrating a real-world application of HETVAL.
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